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Abstract:

A method of forming a shaped container may include providing a metallic
preform. A first pressure may be applied to the metallic preform within a
mold of a shaped container to produce a container part with a partially
formed container shape. The container part with the partially formed
container shape may then be at least partially annealed. A second
pressure may be applied to the container part within the mold to produce
a container part with a fully formed container shape.

Claims:

1.-32. (canceled)

33. A method of forming a shaped container, comprising: providing a
metallic preform; applying a first pressure to the metallic preform
within a mold of a shaped container to produce a container part with a
partially formed container shape; at least partially annealing the
container part with the partially formed container shape; and applying a
second pressure to the container part within the mold to produce the
container part with a fully formed container shape.

34. The method according to claim 33, wherein applying the first pressure
includes applying a pneumatic or hydraulic pressure to the preform.

35. The method according to claim 34, where applying a pneumatic or
hydraulic pressure to the preform includes applying a pneumatic or
hydraulic pressure with a fluid at a temperature above room temperature.

36. The method according to claim 33, further comprising heating the
metallic preform above room temperature prior to applying the first
pressure.

37. The method according to claim 33, further comprising: at least
partially second annealing after applying the second pressure; and
applying a third pressure to the container part within the mold to
produce the container part to produce the container part with the fully
formed container shape.

38. The method according to claim 33, wherein applying a first pressure
includes applying a pressure of at least about 40 Bar.

39. The method according to claim 33, wherein at least partially
annealing the container part includes at least partially annealing a
localized portion of the container part.

40. The method according to claim 33, further comprising: applying at
least one third pressure to the container part; and performing at least
one corresponding at least partially second annealing to the metallic
preform prior to applying the at least one third pressure.

41. A metal vessel, comprising: a metallic open end defining an upper
portion of a cavity of the metal vessel, and configured to receive a cap;
and a metallic closed end opposed to said open end, and defining a lower
portion of the cavity of the metal vessel, said closed end including a
plurality of integrally formed feet that, in part, define the lower
portion of the cavity.

42. The metal vessel according to claim 41, wherein said open end and
closed end are integrally formed with one another, the open end having a
grain structure integral and continuous with a grain structure of the
closed end.

43. The metal vessel according to claim 41, wherein the base has the
plurality of integrally formed feet, each of the feet having a grain
structure integral with a grain structure of the base.

44. A metal vessel, comprising: a metallic open end; a metallic closed
end opposed to said metallic open end; and a metallic sidewall portion
extending between said metallic open end and said metallic closed end,
said metallic closed end including a base portion on which the metal
vessel stands having a grain structure that is integral with a grain
structure of said sidewall portion.

45. The metal vessel according to claim 44, wherein said metallic
sidewall portion and said metallic open end have integral metallic grain
structures.

46. The metal vessel according to claim 44, wherein the base portion
includes a plurality of feet.

47. The metal vessel according to claim 44, wherein said metallic open
end, metallic closed end, metallic sidewall portion, and base portion
define a cavity of the metal vessel.

Description:

RELATED APPLICATIONS

[0001] This Application claims priority to co-pending U.S. Provisional
Application Ser. Nos. 61/835,397 filed Jun. 14, 2013 and 61/884,643 filed
Sep. 30, 2013; the contents of which are hereby incorporated by reference
in their entirety.

BACKGROUND

[0002] Forming metallic containers, such as metallic containers used for
consumer goods, and more particularly, metallic containers for consumer
foods and beverages, has traditionally been performed by making
conventional cans that are sealed with a lid. A variety of different lids
have been used, including a sealed lid that requires a can opener to be
opened and a sealed lid with a pull-tab that enables a user to peel open
the lid. In both of these cases, the lid cannot be re-sealed.

[0003] More recently, metallic containers for beverages have been produced
that are shaped in the form of a bottle. As an example, aluminum and
steel bottles have been formed to resemble the shape of a beer bottle and
sold at sporting events. These bottles are generally thick and are sealed
with a crown cap, as understood in the art. Other metallic containers in
the shape of bottles have been shaped to enable twist-off caps to be
used.

[0004] Metallic containers that can be shaped in the form of a bottle
offer several advantages over cans and glass bottles. First, metallic
containers are more durable and do not shatter upon impact, such as
dropping on a floor. Second, metallic containers are generally more
lightweight than glass containers, thus costing less to ship and making
it easier for vendors to carry. Third, metallic containers are less
expensive than glass. Fourth, with respect to cans, metallic containers
in the shape of bottles provide for easier gripping and offer the ability
to marketers to provide more attractive containers to attract consumers.

[0005] While metallic containers in the shape of bottles ("metallic
bottles") provide certain advantages over other container shapes, such as
cans, and glass bottles, metallic bottles have heretofore been limited in
the shapes that have been commercially feasible to produce. As an
example, the number of steps that it currently takes to manufacture a
shaped metallic bottle is generally over fifty. As a result, the amount
of manufacturing equipment required is particularly high and production
rates are particularly low. As another example, because metal, such as
aluminum alloys or steel, when thinned has limited strength and has the
tendency to bend or crinkle, forming thin metals to produce metallic
bottles is challenging. Because of the tendency for thin metals to bend
or crinkle, certain operations, such as die necking, are challenging and
limits exist as to how much change in diameter can be made in a single
step--historically not much more than 1%-2%. As understood in the art, it
takes upwards of 350 lbs. or more of force to press a crown cap or
twist-off cap onto a metallic bottle. As a result of the strength issues
and capping force requirements, the thickness of the metallic bottles,
especially at the neck and finish of the metallic bottle, has
traditionally been high. While higher thickness of metals results in
stronger bottles, the higher thickness limits the ability to shape
intricate details in the metallic bottles and results in heavier metallic
bottles. The heavier bottle adds to manufacturing and shipping costs, for
example. As such, there is a need to use an alternative technique to
manufacture metallic bottles to overcome thin metal limitations.

[0006] In addition to forming the metallic bottles, decorating metallic
bottles by shaping or applying features to the sidewall of the metallic
bottle is processing intensive as multiple steps are generally used to
shape or apply features to the sidewall. A conventional process for
shaping and applying features to the sidewall includes pressing metal to
apply the desired shape or features to the sidewall while flat prior to
the sidewall being formed into a metallic bottle shape. Such a
conventional process provides limited possibilities, as understood in the
art.

SUMMARY

[0007] The principles of the present invention provide for performing
multiple blow molding operations to metal to produce shaped metal
containers, such as metallic bottles. The metal may start as a metal
preform composed of aluminum, such as aluminum alloys or steel. Because
metal has a maximum strain beyond which the metal ruptures or fails
(e.g., tears), a first pressure, such as pneumatic or hydraulic force,
may be applied to the metal preform to cause the metal preform to reach a
certain strain, and then at least a portion of the metal preform may be
at least partially annealed, thereby causing a stress release in the
metal. After the stress of the metal has been released, a second force,
such as pneumatic or hydraulic force, may be applied to cause any portion
of the metal preform that has not reached its final position within a
mold to stretch to continue moving toward or reach a final position in
the mold. As a result of using multiple blow molding operations, metallic
bottles can be shaped in ways that have heretofore been impossible or
commercially difficult to achieve.

[0008] One embodiment of a method of forming a shaped container may
include providing a metallic preform. A first pressure may be applied to
the metallic preform within a mold of a shaped container to produce a
container part with a partially formed container shape. The container
part may be at least partially annealed with the partially formed
container shape. A second pressure may be applied to the container part
within the mold to produce a container part with a fully formed container
shape.

[0009] One embodiment of a metal vessel may include a metallic open end
defining an upper portion of a cavity of the metal vessel, and be
configured to receive a cap. A metallic closed end may be opposed to the
open end, and define a lower portion of the cavity of the metal vessel.
The closed end may include multiple, integrally formed feet that, in
part, define the lower portion of the cavity.

[0010] One embodiment of a metal vessel may include a metallic open end, a
metallic closed end opposed to the metallic open end, and a metallic
sidewall portion extending between the metallic open end and the metallic
closed end. The metallic closed end may include a base portion on which
the metal vessel stands and having a grain structure that is integral
with a grain structure of the sidewall portion.

[0011] One embodiment of a method of forming a metal container with a
featured sidewall may include providing a blow molded metal container.
The metal container may be positioned into a mold inclusive of at least
one sidewall feature. The metal container may be blown again to cause the
at least one sidewall feature to be created in the sidewall of the
container as defined by the mold. In one embodiment, a sidewall of the
metal container may be at least partially annealed. The sidewall feature
may include a portion of a profile of a sporting good, such as a
baseball, embossed feature (e.g., word), logo, or otherwise. The metal
container may be a shaped metal container. The metal container may be a
partially or fully formed metal container.

[0012] One embodiment of a system for forming a metal container with a
featured sidewall may include providing a mold inclusive of at least one
sidewall feature adapted to receive a blow molded metal container with
the at least partially annealed sidewall. A blowing mechanism may be
configured to blow the metal container again to cause the at least one
sidewall feature to be created in the sidewall of the container as
defined by the mold. The metal container may be a partially or fully
formed metal container.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Illustrative embodiments of the present invention are described in
detail below with reference to the attached drawing figures, which are
incorporated by reference herein and wherein:

[0014] FIG. 1 is a flow diagram of an illustrative process for multi-blow
molding a metallic vessel;

[0015] FIG. 2 is a process diagram of an illustrative process for
multi-blow molding a metalling vessel corresponding with the process of
FIG. 1;

[0016] FIG. 3 is an illustration of an illustrative container shaped as a
bottle inclusive of defined portions, as described herein;

[0017] FIG. 4 is a flow diagram of an illustrative process for creating
features in a sidewall of a container using a multiple blow molding
process; and

[0018] FIG. 5 is an illustration of an illustrative multiple blow molding
process for creating features is a sidewall of a container.

DETAILED DESCRIPTION

Multi-Blow Molding Containers

[0019] With regard to FIG. 1, a flow diagram of an illustrative process
100 for multi-blow molding a metallic vessel is shown. The metallic
vessel may be in the shape of a bottle or any other container, as
understood in the art. Because certain container shapes have dimensions
that are difficult to manufacture using standard metal working
techniques, the principles of the present invention may alleviate
extensive manufacturing processes that allow for shaping metallic vessels
with such dimensions. As an example, many plastic bottles include feet
that define a cavity within the plastic bottle. These feet, however, are
difficult or not possible to form using conventional metal manufacturing
processes because the dimensions are beyond deformation of thin metals
during a conventional blow molding or other metal shaping processes.

[0020] The process 100 starts at step 102, where a metallic preform
("preform") may be provided. The metallic preform may include a variety
of different metallic compositions, including aluminum or steel. In one
embodiment, an aluminum preform is composed of aluminum alloy. The
aluminum alloy may be a 3000 series aluminum alloy, and more
specifically, but not by way of limitation, the aluminum alloy may be a
3104 series aluminum alloy. In providing the metallic preform, it is
contemplated that the metallic preform may be provided by setting the
metallic preform along a manufacturing line to be shaped into a metallic
container, such as a bottle shaped container. Manufacturing of the
metallic preform may be performed by a third-party, such as a metallic
preform manufacturer, such that a bottler may receive and provide the
metallic preform to the manufacturing line. In an alternative embodiment,
a bottler may receive a blank roll of metal, such as aluminum, and create
a metallic preform from that blank sheet to provide the metallic preform
to the manufacturing line.

[0021] The metallic preform may have any of a number of different shapes.
For example, the preform may be tubular in the shape of a cup or cylinder
(i.e., having sidewalls and bottom). The intersection between the
sidewalls and bottom may be squared off (i.e., 90 degrees) or be curved.
Alternative intersection designs may be utilized in accordance with the
principles of the present invention. In one embodiment, the metallic
preform may have a test-tube shape or miniature bottle shape with an open
end and a closed end. If the metallic preform is to be limited to a
portion of an overall container (e.g., a container part) as opposed to
ultimately defining an entire container, then the metallic preform may be
limited in shape and size.

[0022] In addition to the preform having a certain shape, the preform may
have a variety of different thickness dimensions. In one embodiment, the
thickness dimensions are substantially equal along the entire preform.
Alternatively, a bottom portion may be thicker if expansion along the
axial plane may be used to form feet, for example. In one embodiment, if
an upper portion of the preform is to be shaped to be a conventional
closure, an upper portion of the preform may be thicker than the
sidewalls. In one embodiment, the upper portion and bottom portions of
the preform may be thicker than the sidewalls. In manufacturing the
preform, the shaping may be formed with a substantially constant
thickness and portions, such as the sidewalls, of the preform may be
thinned or a shaped preform (i.e., certain portions thicker and thinner
when manufactured). The thickness distribution along the length of the
preform plays a role in the end shape and material distribution of the
container, and may be manipulated or pre-configured to optimize the
process (i) to minimize the weight of the preform and ultimately the
container and/or (ii) to maximize the performance of the final shaped
container.

[0023] At step 104, a first blow molding of the preform may be performed.
The first blow molding may use 40 Bar or more to blow the metal. The blow
molding may use pneumatic or hydraulic pressure blow molding. In one
embodiment, the fluid of the blow molding may be at a temperature above
room temperature, such as 200 degrees Celsius or higher. Lower pressures
may be used to blow the metallic preforms as well. Because thin metals
are limited in deformation due to strain limitations (i.e., an amount of
strain or elongation of which a metal can withstand before fracture), the
strain resulting in deformation of the preform may cause the sidewalls to
extend to contact mold walls within which the preform is positioned,
while other portions of the preform, such as feet, that cannot be fully
formed without fracture cannot reach the mold walls as a result of the
first blow molding at step 104.

[0024] At step 106, the blow molded preform may be (i) locally or entirely
and (ii) partially or fully annealed. That is, a portion (e.g., base or
lower portion) of the blow molded preform or the entire blow molded
preform may be annealed. As understood in the art, annealing causes
stress in the metal to be "reset" or brought back to an initial
stress-relieved state (also known as stress relaxation). That is, the
grains of the metal that have been deformed (i.e., stretched or reshaped)
and stressed are reset to an initial zero stress or stress relieved
state. Partially annealing causes stress in the metal to be brought to a
lower stress-relieved state, but not fully stress-relieved to an initial
state. By at least partially annealing to reset the stress of the blow
molded preform, another blow molding can be performed that lowers the
risk of a subsequent blow molding from over-stressing the metal to cause
the metal to fail. In one embodiment, rather than fully annealing the
entire preform or localized portion of the preform, the annealing
performed at step 106 may reduce the stress to a level that accommodates
further desired deformation, but is not zero stress. For example, the
preform may be partially annealed or normalized, both of which are
considered equivalent in function. By providing for a partial annealing,
time and energy may be reduced in the manufacturing process, thereby
saving cost and improving production rate. In some cases, depending on
the final container geometry desired, annealing prior to a subsequent
(e.g., second) blow molding may not be necessary if the amount of strain
that the metal will undergo in the subsequent blow molding process will
be less than a strain that will cause the metal to fracture or otherwise
deform.

[0025] At step 108, a second blow molding may be performed to the blow
molded preform after the annealing process. The second blow molding 108
may cause portions of the blow molded preform to further deform to extend
to the mold walls in which the blow molded preform resides. As an
example, feet of a bottle that cannot be fully formed during the first
blow molding at step 104 may be further deformed to reach the mold walls
defining feet during the second blow molding 108. Because it may not be
possible for two blows to cause the preform to fully deform to reach the
mold walls, steps 106 and 108 may be repeated multiple times until the
preform is fully molded. It should be understood, however, that the
number of anneals and blows at steps 106 and 108 may be limited to the
amount of stretch possible for the preform, which may be defined by the
thickness of the metal, metal type, amount of annealing, and so on. In
one embodiment, the fully shaped preform (e.g., bottle shape) may be left
in whatever strain-hardened condition it is in after the second blow
molding at step 108. Alternatively, the fully shaped preform, or portion
thereof, may be fully or partially annealed to reset the metal to a less
stressed state. Being in a strain-hardened state, however, may allow the
container to be more durable for manufacturing, shipping, and consumer
use. There may be commercial reasons for having the container be somewhat
more pliable, so partial or full annealing may be performed after the
container is fully shaped.

[0026] FIG. 2 is a process diagram of an illustrative process 200 for
multi-blow molding a metallic bottle corresponding with the process 100
of FIG. 1. The process 200 may start by providing a preform 202. A mold
204, which may be formed of single or multiple segments, may be provided.
As understood in the art, the preform 202 may be disposed within the mold
204, to be blown. As previously described, in blowing the preform,
pressure, such as 40 Bar or higher, may be applied within the preform to
cause the preform to strain and deform. As a result of the deformation,
the metal may be strain-hardened ("hardened"), as understood in the art.
As shown, the preform 202 may result in a partially molded preform 202'
that contacts certain portions of the mold (e.g., sidewalls), while other
portions of the preform 206a do not contact other portions of the mold
208, which, in this case, are feet of a bottle mold. Other shapes, such
as single or concentric rings, at the base may be produced using the
multi-blow molding process described herein.

[0027] A heat element 210, which may be an oven, heating element, open
flame, or other heat source, may be used to perform whole or localized
annealing, either fully or partially annealed, of the partially molded
preform 202'. If a localized annealing process of the partially molded
preform 202' is performed, then portions of the partially molded preform
202' remain in a strain-hardened state, while the annealed portions of
the partially molded preform 202' are partially or entirely stress
relieved and available for further blowing and deformation.

[0028] Continuing with FIG. 2, a second blow molding may be performed on
the partially molded preform 202' to cause the partially molded preform
202' to continue being deformed. As shown, portions 206b of the partially
molded preform 202' that were not fully deformed may be fully deformed so
as to contact the other portions of the mold 208. As described with
regard to FIG. 1, the process 200 may provide for multiple blow molding
and annealing processes to fully deform the preform 202 into a fully
molded preform 202''. That is, the second blow molding may actually be a
third or forth blow molding with intermittent annealing processes to at
least partially reset the stress of the metal of the partially molded
preform 202'.

[0029] Because the feet may be formed in a second or higher blow molding
process, the portions 206b defining the feet may use a higher strain than
other portions of the container, such as the sidewalls, which may extend
to the mold 204 in a first or fewer blows. And, if the entire preform
202, which is being shaped into a container part, which may include being
an entire container, is annealed between blows, the portions 206b will
have a higher strain-hardness than other portions of the fully molded
preform 202''. If an annealing process is performed between blow
moldings, such as annealing the portions 206a that are being shaped into
feet, then the blow molding process may strain-harden the portions 206b
to a higher level than other portions of the fully molded preform 202''.
And, because the axial depth of the portions 206b are greater than other
portions of the fully molded preform 202'', such as the radially shaped
sidewalls or open end, deformation of the portions 206b are higher than
deformations of the other portions of the fully molded preform 202''.

[0030] With regard to FIG. 3, an illustration of an illustrative metallic
container 300 shaped as a bottle inclusive of defined portions, as
described herein, is shown. The container 300 includes an open end 302
and closed end 304. The open end 302 and closed end 304 are shown to be
divided along a tapering portion of the container 300. It should be
understood, however, that the open and closed ends 302 and 304 may have
an alternative location along the container 300 at which each starts and
stops. In accordance with the principles of the present invention, a
preform may be configured to be formed into one, both, or a subsection of
one of the open end 302 and closed end 304.

[0031] The open end 302 may include a finish region 306 that generally
includes a threaded portion 307 and may or may not include carry ring
309, which is used during manufacturing of the container 300. A neck
portion or neck 308 may be a tapering section extending from a sidewall
portion or sidewall 310 to the finish portion 306. The sidewall portion
may also be considered to include the neck portion 308. A base portion or
base 312 may be a bottom portion of the container 300 on which the
container rests. The base portion 312 may include multiple feet 314, such
as, for example, at least two feet 314 that may, in part, define a cavity
of the container 300 in which a beverage is stored. Further, the feet 314
may have any shape, such as, for example, individual external protrusions
disposed about the circumference of the base 312 and/or rings
concentrically disposed about one another and protruding from or
defining, in part, the base 312.

[0032] As shown, a profile of the sidewall portion 310 is shown to be
shaped. Because the sidewalls have limited variance (e.g., a waist), the
blow molding process of FIG. 1 may accommodate for the shaping of the
sidewall portion 310 in a single blow, where the feet 314, which are
larger protrusions, may need two or more blow molds with intermittent
annealing, either full or partial annealing, to enable the preform metal
to extend to fully form the feet 314. A cap (not shown), which may be
metal or plastic, may be used to seal the container with fluid therein,
as understood in the art.

[0033] Referring back to FIG. 2, because the metallic preform 202 may be
used to shape the portions 206b (i.e., feet 314) along with other
portions of the fully molded preform 202'', such as the base 312,
sidewall 310, neck 308, and finish 306, a grain structure of the metal
may extend between the open end 302 and closed end 304. In one
embodiment, a container part may include feet 314 and base 312, where the
base 312 may extend or be attached to the sidewall 310. In one
embodiment, the container part is inclusive of an entire container with
the exception of a cap as capable of being produced by a metal preform
inclusive of a finish with or without threads, as understood in the art.
Metallic grain structures may extend between the feet 314 and base 312
inclusive of a portion of sidewall above the feet 314. That is, the grain
structures may extend and be continuous between multiple portions of the
container 300 (e.g., neck and sidewalls, sidewalls and base and/or feet).
The feet 314, thus, may have an integral and continuous grain structure
with the base 312 and/or the sidewall 310 of the container 300. And, as a
result, the feet 314 are integral with the closed end 304 and define
cavity within the container 300. Although the base 312 is shown as having
feet 314, it should be understood that alternative shapes and
configurations may be formed using the multi-blow molding process
described herein.

Multi-Blowing Sidewall Features into Containers

[0034] In addition to the principles of the present invention providing
for producing blow molded metallic containers, such as bottles, that are
thin and have features that are not part of the general shape of the
containers. In one embodiment, the features may extend beyond features
that are possible to create from a single blow due to the metal extending
beyond a strain limit. For example, utilizing the principles of the
present invention, three-dimensional (3D) designs, such as sports items,
logos, cartoon characters, etc., may be created in the sidewalls.
Furthermore, the principles of the present invention provide for
producing containers with high resolution sidewall features, such as
embossing or other decoration style or feature. As with the previously
described multiple blows separated by at least a partial annealing
process therebetween to at least partially stress relieve metal, multiple
blows separated by at least partially annealing the sidewalls, may be
utilized. Such a multiple blow molding process may enable a feature, such
as embossing, to be added to the sidewalls of the container. In one
embodiment, the annealing may be localized in a limited region of the
sidewall or the entire sidewall may be annealed (or partially annealed).
The amount of annealing may vary from zero to a full stress-relieved
metal depending on an amount of strain that exists in the previously
blown sidewall, expansion of the sidewall to form the feature(s), detail
in the feature(s), and so on.

[0035] For the purposes of this application, a "feature" created through a
secondary blow molding process (i.e., either a second or later blow
molding of at least a portion of a container) and applied to a sidewall
of a container. A feature may be any geometrical, material or process
related feature where the sidewall of the container is either deformed or
formed from the previous stage of forming that the container has gone
through, or in the case of a mold where it is subjected to forces and
deforms permanently to conform partially or fully to the mold surface.
Therefore, any geometrical, material attachment or process treatment that
makes part of or the entire sidewall to undergo any permanent deformation
compared to the previous shape and form of the container sidewall can be
considered a feature on the sidewall.

[0036] With regard to FIG. 4, a flow diagram of an illustrative process
400 for creating features in a sidewall of a container using a multiple
blow molding process is shown. The process 400 may start at step 402,
where a metal container may be provided. The metal container may be
aluminum, steel, or any other thin metal that may be used for a beverage
container, as previously described herein. Although the principles of the
present invention provide for the metal container to have been previously
blow molded to be a "blank" metal container (i.e., a container without
any sidewall features), non-blow molded metal containers may also be
utilized in accordance with the principles of the present invention. At
step 404, a sidewall of the metal container may be at least partially
annealed. In at least partially annealing the sidewall, the sidewall may
be heated, either locally (i.e., a portion of the side wall) or entirely
(i.e., the entire sidewall may be heated), to cause the sidewall to be
respectively stress relieved partially (i.e., to remain above a zero
stress state) or entirely (i.e., to a zero stress state).

[0037] At step 406, the container with the at least partially annealed
sidewall may be positioned into a mold with a sidewall feature. The mold
may be a multi-segment mold (e.g., three segments, including two sidewall
forming segments and one base forming segment). In one embodiment, the
mold with the sidewall feature may the same or different mold than a mold
used to originally form the "blank" container. If the same mold, then the
features of the sidewalls may not have been fully formed in the initial
blow process due to feature shape, resolution, or distance from center of
the container. The container may be a portion or complete container.
Positioning of the container within the mold may be performed
automatically, as understood in the art.

[0038] The mold may be sized substantially the same as a mold, if
different, from the mold that formed at least a portion of the container
(e.g., portion of the container below a finish (i.e., top portion of a
bottle that includes the threads)), with the exception of a feature
defining portion of the mold used to form a feature in the container. In
one embodiment, the feature defining portion may protrude outward from
the mold, where an inside wall of the mold protrudes from the surrounding
portion of the inside wall of the mold that is shaped to otherwise
substantially match the container. In another embodiment, the feature
defining feature may extend inward from the surrounding portion of the
inside wall of the mold that is shaped to otherwise substantially match
the container. If an inward defining feature is utilized, a low,
pre-pressure may be applied to the container prior to contacting the mold
to the container, thereby minimizing chances of the container being
deformed as a result of the contact prior to applying a higher pressure
(step 408) to cause the inward feature to be formed in the container. In
one embodiment, the pre-pressure may be 5 Bar or less, and the higher
pressure may be 40 Bar or higher. Alternatively, low and high pressures
may be utilized in accordance with the principles of the present
invention.

[0039] At step 408, the container may be blown to cause features to be
created in the side wall of the container as defined by the mold. In
being blown, and as described above, higher pressure, such as 40 Bar, may
be applied to the mold and container. The pressure applied to the
container may be applied using a step function, where the pressure ramps
from a first pressure level to a second pressure level in a short period
of time (e.g., less than 0.25 seconds). As a result of blowing the
container at the higher pressure, the sidewalls of the container may be
expanded to be formed by the features of the mold. And, because the
sidewalls of the container have been at least partially annealed, the
sidewall portions that are altered to be formed into features may be
hardened from their softened state as a result of being annealed. Hence,
the features may end up having different hardness than surrounding
portions of the sidewall that were not altered by the features defined by
the mold. It should be understood that because the features of the
sidewall may have different distances extending from or into the
sidewall, that the hardness of the features, too, may vary depending how
much stretching or deformation occurs from a feature being formed in the
sidewall of the container. For example, in the case of a portion of a
baseball feature with stitching features being formed from a sidewall of
an aluminum bottle, a portion of the baseball feature that is farthest
from the cylindrical shape of the sidewall (or center of the bottle
itself) has the most stretch, and is therefore the most strain-hardened,
while the portion of the baseball feature that is closest to the
cylindrical shape of the sidewall is less strain-hardened as a result of
having the least stretch from the feature forming process. Moreover, the
stitching features that are part of the baseball feature may have a
different hardness than the spherical portion of the baseball feature as
a result of extending from the spherical portion and having details
formed by small deformations.

[0040] With regard to FIG. 5, an illustration of an illustrative multiple
blow molding process that corresponds to the process 400 of FIG. 4 for
creating features in a sidewall of a metal container 500 is shown. The
process may provide the metal container 500. The metal container 500 may
be a whole container or a portion of a container (e.g., lower portion
inclusive of a base). The container may be positioned near a heat source
502 that includes one or more heating elements. In positioning, the heat
source 502 may be moved to be in proximate location to the container 500
or the container 500 may be moved to be in proximate location to the heat
source 502. The heat source 502 may heat a local region or entire
sidewall of the metal container 500 to at least partially anneal the
sidewall. In an alternative embodiment, if the sidewall is not expanded
to a failure point, then the sidewall can be blown further without
fracturing the sidewall when forming a feature in the sidewall. It should
be understood that the depth of the feature to be created on the sidewall
may be used to determine whether or not the sidewall can be blown without
causing failure of the sidewall by blowing a second time without at least
partially annealing the sidewall (or may be used to determine how much
annealing is to be performed).

[0041] A mold includes multiple mold pieces or segments 504a, 504b, and
504c (collectively 504) that include three mold features 506a (baseball
half), 506b (baseball half), and 506c (embossed words) (collectively
506). It should be understood that the number of features may be one or
more. The mold pieces 504 may form a complete mold when the mold pieces
504 are moved together using motions 508a, 508b, and 508c (collectively
508) using any electromechanical, hydraulic, pneumatic, or other process,
as understood in the art. The complete mold may have substantially
identical dimensions as the mold that created the container (i.e.,
length, width, and profile that does not allow the container to deform in
any region other than the feature region(s). In one embodiment, the mold
may be the same mold that created the container. However, by using a
separate mold (i.e., one without features and one with features), "blank"
containers may be formed that can thereafter have feature(s) applied
thereto, and those feature(s) may be different for different purposes.
The different purposes may include different events (e.g., baseball,
football, auto racing, Olympic games, college events, etc.) or any other
purpose (e.g., company logos, college logos, city memorabilia, cartoon
characters, etc.). Moreover, small numbers of metallic containers with
specific features may be produced from "blank" containers in an
affordable manner and in a dynamic manner through use of a dynamic
manufacturing system with one or more blow molding stations. In one
embodiment, rather than using fixed molds, pixelated, dynamically
configurable molds may be utilized that allow for three-dimensional (3D)
features to be dynamically created to form the features.

[0042] After the mold is formed and positioned around the container 500,
the container 500 may be blown 510 using a blowing mechanism, as
understood in the art, via an opening in the container to cause a
pressure, such as 40 Bar or higher, to force the sidewalls to expand into
the features 506 of the mold. Resulting from the blow, molded features
512a, 512b, and 512c are created in the sidewall of the metal container
500. Depending on the resolution of the features to be created in the
sidewall, the amount of pressure, amount of annealing, and/or other
factors may be adjusted to accommodate the desired resolution, where the
resolution includes intricacies or detail of the features. More
specifically, as the metal is blown a first time, as the metal is
stretched, it becomes strain-hardened, which may limit the ability for
the metal to be shaped to have high resolution of a feature. As such, by
at least partially annealing the metal, the metal can be better shaped to
be formed with high resolution features. As an example, general shape of
a football feature is considered low resolution, while stitching in the
football is considered higher resolution. A team mascot, such as an
eagle, may also have high resolution features (e.g., feathers, fur, eyes,
etc.). Other features with different resolutions are possible. It should
be understood that any feature shape that can be created in a mold and
that the sidewall can withstand being formed into the feature without
rupturing may be utilized in accordance with the principles of the
present invention.

[0043] Blow molding a metal preform to create at least a portion of a
metal container is one technique for producing a shaped metal container
with sidewalls with features. Another technique for creating a shaped
metal container with sidewall features may alternatively include starting
with a straight wall cylinder formed using blow molding or fabrication
techniques that do not use include blow molding. As such, cans or other
shaped metal containers may utilize the multiple blow molding principles
of the present invention to create metal containers with sidewalls
inclusive of features.

[0044] One embodiment of a method of forming a container with a featured
sidewall may include providing a blow molded metal container. The metal
container may be positioned into a mold inclusive of at least one
sidewall feature. The metal container may be blown again to cause the
sidewall feature(s) to be created in the sidewall of the container as
defined by the mold. The metal container may be a partially formed metal
container or fully formed container. The process may further include
partially or fully annealing a sidewall of the metal container. In
annealing, either partially or fully, the sidewall may be heated to a
temperature that causes metal grains of the sidewall transition to a
reduced stress state from an existing stress state. In annealing the
sidewalls, either partially or fully, a localized portion of the sidewall
may be heated. Positioning the metal container in the mold may include
moving multiple mold pieces about the metal container, where the mold
pieces, when integrated or in contact with one another, have a profile
that substantially matches a profile of the container with the exception
of the sidewall feature(s) of the mold. In one embodiment, the sidewall
feature(s) include a portion of a profile of a sporting good. In one
embodiment, a sidewall feature may include an embossed feature, such as a
word or otherwise. The metal of the sidewall feature(s) has a different
hardness than metal surrounding the sidewall feature(s). In providing a
metal container, a shaped metal container may be in a shape of a bottle.

[0045] One embodiment of a system for forming a metal container with a
featured sidewall may include a mold inclusive of at least one sidewall
feature, and adapted to receive a blow molded metal container. A blowing
mechanism may be configured to blow the metal container again to cause
the sidewall feature(s) to be created in the sidewall of the metal
container as defined by the mold. The metal container may be a partially
formed metal container or a fully formed container. The system may
further include a heater configured to at least partially anneal the
sidewall of the metal container. Moreover, the heater may be configured
to at least partially anneal the sidewall to a temperature that causes
metal grains of the sidewall to transition to a reduced stress state from
an existing stress state. In one embodiment, the at least partially
annealed sidewalls may heat a localized portion of the sidewall. The mold
may include multiple mold pieces configured to be formed about the metal
container, where the mold pieces, when integrated or in contact with one
another, have a profile that substantially matches a profile of the
container with the exception of the sidewall feature(s) of the mold. The
sidewall feature(s) may include a portion of a profile of a sporting
good. The sidewall feature(s) may include an embossed feature, such as a
word. The sidewall features may have different resolutions (e.g., low and
high, including high resolution features extending from low resolution
features). Metal of the at least one sidewall feature may have a
different hardness than metal surrounding the at least one sidewall
feature. In one embodiment, the metal container may be in the shape of a
bottle.

[0046] The previous detailed description is of a small number of
embodiments for implementing the invention and is not intended to be
limiting in scope. One of skill in this art will immediately envisage the
methods and variations used to implement this invention in other areas
than those described in detail. The following claims set forth a number
of the embodiments of the invention disclosed with greater particularity.